Three dimensional mailer

ABSTRACT

The three dimensional mailer has multiple stacked layers forming a pocket to accept and transport a sample to an intended recipient. The middle layer has the overall dimensions of the mailer in a generally rectangular shape with a rectangular opening die cut to admit a sample. The thickness of the middle layer is determined by the thickness of the sample. The top layer attaches above the middle layer and has a die cut tab for accessing the opening in the middle layer. The bottom layer opposite the top layer provides a backing to the opening. Preferably, the top layer, middle layer, and bottom layer are separate pieces laminated together. Alternatively, the top layer and the bottom layer are contiguous and joined with a spine whereupon the top layer and bottom layer fold upon the spine to contain the middle layer.

BACKGROUND OF THE INVENTION

This three dimensional mailer relates to sampling devices and morespecifically to an improved card for containing a sample. A uniqueaspect of the present mailer is a pocket accessible through a hingedtab.

Advertisers and companies have sent samples by mail for years. Samplesare printed upon the cards as in cosmetic and fragrance samples orattached to the cards as in trinkets and mailable products. Printed andattached samples run the risks inherent in travel through the mails.Printed samples can become damp and lose their effectiveness. Attachedsamples can fall off a card never to reach the intended recipient.Samples can also be placed within other publication such as magazines,coupon mailers, and the like. Sample inside another publication haveprotection from the hazards of the mails yet impose the higher cost of apublication upon the intended recipient.

Beyond samplers, the advertising and marketing industries seek aninexpensive mailer that has thickness and carries a sample. As attachedsamples risk the hazards of the mails, samples within a mailer avoidmany of the troubles in mailing. A sample within a mailer is protectedon all sides by the body of the mailer. However, the mailer must stillmeet postal requirements and be cost effective to manufacture and tomail. The thickness of a mailer determines the size of a samplecontained therein. Generally a larger sample weighs more. Thus thickermailers face limits on their height and length like other card mail, andon thickness due to postage costs measured by weight.

The difficulty in providing a three dimensional mailer is shown by theoperation of typical mailers. The patent to Jones, U.S. Pat. No.805,106, shows an advertising and mailing card, which has foldablyprovided therein a series of linked cards or advertising blanks, whichwhen embedded within the card proper, and its cover closed, provides forstorage of the cards therein. The cover, appears to have a window in it,apparently for viewing of the top card within the card proper. Thisparticular prior art, from 1905, at least shows a type of advertising,that stores within a card, and has a cover that overlays the same duringclosure.

The patent to Unger, U.S. Pat. No. 1,957,374, shows an advertisingdevice which is claimed as a blotter, and has a removable layer throughweakened severance lines that can be removed for providing a returnedmailing card for the recipient.

The patent to MacHarg, U.S. Pat. No. 2,256,399, shows another mailingcard. While portions of the card may be removable apparently to removethe disclosed picture, this device does not appear to be big enough toaccommodate any type of novelty item or sample.

The patent to Casanovas, U.S. Pat. No. 2,717,174, shows another postcardor other card with a fragrant pastille. This is just a postcard with apull tab that allows immediate access to the perfume pastille andprovides a mailer for a perfume sample.

The patent to Eisen, U.S. Pat. No. 2,844,901, shows another laminatedtype of greeting card, identified as a display assembly. It is capableof holding a cut-out portion, which may function as a novelty item. Theportion appears to be some type of an intermediate filler part, for theassembly. But, this device is identified as an assembly, for displaypurposes, and is not necessarily for mailing purposes.

The patent to Takeuchi, U.S. Pat. No. 4,590,111, shows a fragrancereleasing sheet article and method of making the same. This is a releasesheet, for an article that may be used as a fragrance sampling means, orat least for releasing a fragrance, when it is opened. You can see thestructure of the device, it includes its exterior member, having a baseplate, a colored pattern on a film, and apparently the fragrance isapplied to one of these inner members, such as the releasing member.

The patent to Dojel, U.S. Pat. No. 4,705,301, shows an entrance ticket.This is some type of a flexible rectangular carrier, which can be tornopen to reveal the location of a seat.

The patent to Norman, U.S. Pat. No. 4,892,246, shows a postcard with atear out return postcard. The present invention is not a postcard in thefirst instance, nor does it have a tear out portion that can bereturned. The present invention is not a business form, and this isgenerally what is defined in the claims of this particular patent.

The patent to Tararuj, U.S. Pat. No. 4,923,063, shows a sample packetfor creams and methods of manufacture, not a mailer. It does define theinclusion of a paper sheet within its interior that prevents absorbingany cream, as a sample. The sample packet defines first and secondpanels, with a line of adhesive applied to one of the panels, that foldover the reservoir of cream, to seal it therein. It also has a frangibleopening means, as the pull tab, that can open the sample packet toprovide access to the cream.

The patent to Lithwick, U.S. Pat. No. 4,951,404, defines a greeting cardor the like. While this card does provide a container, to function as awindow, in the center of the card, for holding items, this really is notthe structure of the present invention.

The patent to Franklin, U.S. Pat. No. 5,255,456, shows a double layercard unlike the tri-layer, such as the present invention. Furthermore,at its additional area, it is designed for peeling off, during usage.

The patent to Colvin, Jr., et al., U.S. Pat. No. 5,257,823, is upon apersonalizable paper product and method. This is just a card where thefront has a series of pull open doors and where the back may have noticerelating to a party written therein.

The patent to Garrison, et al., U.S. Pat. No. 5,890,743, is a protectedcard intermediate and method. This is an imprintable card where you canwrite on it, and it provides a marking, where the upper transparentlayer is a film in contact with a release material for apparentlyproviding a form of printing thereon.

The patent to Berman, et al., U.S. Pat. No. 5,953,885, shows anothercosmetic sampler and method of making using bulk thin film applicationtechniques. This sampler is not really made out of sheets of thin film,but is laminated together, in the manner of this invention. The presentinvention incorporates that thicker intermediate layer, and a trinket,promotional item, or sample, can be supplied therein, but it is not madeof a series of webs.

The patent to Best, et al., U.S. Pat. No. 6,092,841, does show apromotional one-piece mailer assembly having an integral coupon card.This particular mailer is at least a five-piece item, having perhapseven a seven-piece laminate, for furnishing coupons. While the presentinvention may be a form of laminate, it IS does not include a pluralityof mini-coupons, within a variety of card stock layers that form itsstructure.

The patent to Berman, et al., U.S. Pat. No. 6,182,420, shows anothermethod of making a cosmetic sampler using bulk thin film applicationtechniques. Once again, the present invention is really not made outthin web materials, for holding cosmetics. This sampler in this patentis not for use for mailer purposes.

The patent to Gu, U.S. Pat. No. 6,282,819, is a design and manufactureof a communicating card. Your mailer does not include any type ofelectronic module in it that incorporates electronic circuitry, and itjust would not be related to the structure and usage of thecommunicating card as defined and claimed in this particular patent.

The patent to Fuchs, et al., U.S. Pat. No. 6,520,329, is a packaging forplaniform objects and products. This particular package is for holdingplaniform objects, such as pharmaceutical flat bodies, susceptors,cachets, wafers, transdermal therapeutic systems, and drug deliverysystems, chewing gum, microchips, and the like. The packaging, asdefined in the claims, includes a support card, with cavities therein.Then, a cover film is applied over the cavities, for sealing the objectsinside. Then, it includes a flat envelope that surrounds the supportcard. The present invention is just not fabricated in the exact manneras defined in the claims of this particular patent.

The patent to Berman, et al., U.S. Pat. No. 6,691,872, discloses amethod of making a cosmetic sampler using bulk thin film applicationtechniques. This is similar to the previous Berman patents, where theyare laminating various sheets of material together, generally of a thinlayer of material, and adhering these layers together to hold a cosmeticfor sampling purpose therein. This is not a mailer, and it is formedmore as a sampler, rather than for holding any promotional type of threedimensional item. The films used in this patented device may be one ortwo thousandths of an inch.

The patent to Kalvelage, et al., U.S. Pat. No. 6,802,422, discloses asealed blister assembly which is not the present invention. Then thepatent to French, et al., U.S. Pat. No. 6,830,153, is a child-resistantblister pack which is not the form of the present invention. Finally,the design patent to Stamm, Jr., et al., No. D496,268, shows anotherdesign for a blister pack which again is not the present invention.

The present art overcomes the limitations of the prior art. That is, inthe art of the present invention, a three dimensional mailer, isprepared with a middle layer having an opening bounded by top and bottomlayers. The top layer is opened to insert a sample and the bottom layerserves as a back for the opening and contains the sample.

SUMMARY OF THE INVENTION

The three dimensional mailer has multiple layers stacked upon oneanother forming a pocket to accept and transport a sample to an intendedrecipient. The middle layer has the overall dimensions of the mailer ina planar shape, generally rectangular, with a rectangular opening diecut to admit a sample. The thickness of the middle layer is determinedby the thickness of the selected sample of product but limited by weightbased postage costs. The top layer attaches above the middle layer andhas a similar shape as the middle layer but has a die cut tab foraccessing the opening in the middle layer. The bottom layer opposite thetop layer has a planar shape similar to the middle layer and provides abacking to the opening. In the preferred embodiment, the top layer,middle layer, and bottom layer are separate pieces laminated together.In an alternate embodiment, the top layer has a flap hingedly connectedthat folds over the present invention. Alternatively, the top layer andthe bottom layer are contiguous and joined with a spine whereupon thetop layer and bottom layer fold upon the spine to contain the middlelayer therebetween.

Numerous objects, features and advantages of the present invention willbe readily apparent to those of ordinary skill in the art upon a readingof the following detailed description of presently preferred, butnonetheless illustrative, embodiments of the present invention whentaken in conjunction with the accompanying drawings. In this respect,before explaining the current embodiment of the invention in detail, itis to be understood that the invention is not limited in its applicationto the details of construction and to the arrangements of the componentsset forth in the following description or illustrated in the drawings.The invention is capable of other embodiments and of being practiced andcarried out in various ways. Also, it is to be understood that thephraseology and terminology employed herein are for the purpose ofdescription and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception,upon which this disclosure is based, may readily be utilized as a basisfor the designing of other structures, methods and devices for carryingout the several purposes of the present invention. It is important,therefore, that the claims be regarded as including such equivalentconstructions insofar as they do not depart from the spirit and thescope of the present invention.

It is therefore an object of the present invention to provide a new andimproved three dimensional mailer that has all of the advantages of theprior art mailers and none of the disadvantages.

It is another object of the present invention to provide a threedimensional mailer that may be easily and efficiently manufactured andmarketed.

Even still another object of the present invention is to provide a threedimensional mailer that has a middle layer that varies in thickness toaccommodate various size samples such as trinkets, candy, tubes ofcosmetic, and the like.

Even still another object of the present invention is to provide a threedimensional mailer that has a middle layer with an opening cut thereinfor a sample, a top layer that provides access to the sample, and abottom layer that serves as the back of the opening to retain thesample.

Even still another object of the present invention is to provide a threedimensional mailer that can be mailed within regulation sizes at aminimum of weight and hence postage.

Even still another object of the present invention is to provide a threedimensional mailer that has low production cost.

Even still another object of the present invention is to provide a threedimensional mailer made from the fewest layers possible.

Lastly, it is an object of the present invention to provide a threedimensional mailer that fits within existing publications such asmagazine and envelope coupon mailers.

These and other objects may become more apparent to those skilled in theart upon review of the invention as described herein, and uponundertaking a study of the description of its preferred embodiment, whenviewed in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a top view of the preferred embodiment of the threedimensional mailer constructed in accordance with the principles of thepresent invention;

FIG. 2 shows a sectional view through the pocket of the preferredembodiment;

FIG. 3 has an exploded view of the preferred embodiment;

FIG. 3A has an exploded view of an alternate embodiment of the toplayer;

FIG. 4 describes a top view of an alternate embodiment of the presentinvention;

FIG. 5 describes a sectional view through the pocket of the alternateembodiment and shows the spine;

FIG. 6 shows a top view of the alternate embodiment unfolded and withoutthe middle layer;

FIG. 7 has an exploded view of the alternate embodiment prior toassembly; and,

FIG. 8 shows the alternate embodiment assembled with the top layer openrevealing the pocket.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The present art overcomes the prior art by providing a three dimensionalmailer, generally rectangular in shape, that contains a sample thereinfor delivery to and opening by the recipient of the mailer. Turning toFIG. 1, the preferred embodiment of the mailer 1 has a top layer 5generally rectangular in shape. The top layer has a tab 7 located abovethe opening 4 in the middle layer 3, here shown as centered though otherlocations are anticipated. The rectangular tab is formed by a fold line8 upon one lateral edge 6 and then intermittent linear scoring 9 uponthe longitudinal edges and the remaining lateral edge. The remaininglateral edge has a partial knob 10 that extends into the top layer 5 andaway from the tab 7. The tab is generally much smaller in dimensionsthan the mailer. The recipient of the mailer works the knob free fromthe mailer then pulls the knob towards the fold line thus opening thetab. Behind the tab, the recipient removes the sample contained withinthe pocket.

The pocket 11 appears in FIG. 2 as a portion of the middle layer 3, oneof three layers in the preferred embodiment. The middle layer 3 has agenerally rectangular shape to match the top layer 5. The middle layerhas a thickness suitable to the sample placed within the mailer. Thepocket is formed by removing a rectangular shaped central portion 4 ofthe middle layer 3. Opposite the top layer, the preferred embodiment hasthe bottom layer 2. The bottom layer has a rectangular shape also tomatch the top layer. The bottom layer is continuous and has no scoringor openings there through. The bottom layer serves as the backing to thepocket and assists in retaining a sample in the pocket along with thetop layer.

The layers of the preferred embodiment are assembled as shown in FIG. 3.The bottom layer is placed down first then an adhesive is applied to thebottom layer. Then the middle layer is applied to the adhesive surfaceof the bottom layer. The middle layer is oriented to match the shape ofthe bottom layer. Then further adhesive is applied to the middle layeropposite the bottom layer. A sample is then placed within the opening ofthe middle layer. The sample is slightly less in thickness than themiddle layer and fits within the dimensions of the opening. Next, thetop layer is applied to the middle layer upon the adhesive. The toplayer is oriented to also match the shape of the bottom layer and themiddle layer. The top layer is then positioned so the tab is centeredupon the opening in the middle layer and above the sample. The threelayers are then pressed together to firmly bond them and the samplewithin a pocket formed by the three layers.

In an alternate embodiment shown in FIG. 3A, the top layer 5, has a flap6 a that folds over the top layer 5. The flap 6 a joins to the top layeron a fold line 6 b or living hinge, generally along a longitudinal edgeof the mailer 1 and preferably towards the upper edge of the finishedmailer. When folded, the flap has similar dimensions to the top layer.In a still further alternate embodiment, the bottom layer 2 also has aflap of similar construction as the flap for the alternate embodiment ofthe top layer as described. In a still further alternate embodiment, thetop layer 5 has a flap in a fan fold configuration with multiple sheetsbetween the flap and the top layer. In a still further alternateembodiment, the top layer has a flap in an accordion fold configurationwith multiple sheets hingedly connected on alternating longitudinaledges. In this alternate embodiment, the flap expands outwards from thetop layer and displays multiple surfaces of the sheets for printing ofmarketing messages.

FIG. 4 though shows an alternate embodiment of the mailer that has aspine 12 upon a longitudinal edge. The alternate embodiment has a toplayer 5 generally rectangular in shape and a tab 7 generally centered inthe top layer as previously described. The top layer 5 joinscontiguously to the bottom layer along a spine 12, here shown as the toplongitudinal edge. The top layer has a rectangular tab that forms upon afold line 8 upon one lateral edge and then intermittent linear scoring 9upon the longitudinal edges and the remaining lateral edge. Theremaining lateral edge has a partial knob 10 that extends into the toplayer. The tab is generally much smaller in dimensions than the mailer.The recipient of the mailer works the knob free from the mailer thenpulls the knob to open the pocket 11 revealing the sample containedinside. Behind the tab 7, the recipient removes the sample containedwithin the pocket.

The pocket 11 appears in FIG. 5 as a portion of the middle layer 3, oneof three layers in the preferred embodiment. The middle layer has agenerally rectangular shape to match the top layer. The middle layer hasa thickness suitable to the sample placed within the mailer. The pocket11 is formed by removing a rectangular shaped central portion of themiddle layer. Opposite the top layer, the alternate embodiment has thebottom layer 2. The bottom layer has a rectangular shape also to matchthe top layer. The bottom layer is contiguous with the top layer throughthe spine located across the top longitudinal edge of the middle layer.The bottom layer is continuous and has no scoring or openings therethrough. The bottom layer serves as the backing to the pocket andassists in retaining a sample in the pocket along with the top layer.

With the middle layer removed, the alternate embodiment has thecontiguous top layer 5 and bottom layer 2 shown in FIG. 6. The top layeris shown towards the left having a generally rectangular shape with theknob of the flap upwards. Upon a longitudinal edge of the top layer, thespine 12 joins to the top layer generally centered between the top layerand the bottom layer. The spine has a width approximately that of thethickness of the middle layer. The spine is flanked by a pair of foldlines to which the top layer and bottom layer fold respectively. Upon anedge of the spine, a longitudinal edge of the bottom layer joins thespine opposite the top layer.

The layers of the preferred embodiment are assembled as shown in FIGS. 7and 8. The bottom layer 2 is placed down first with the spine 12 locatedtowards the top of the invention and the top layer 5 opening upwards.Then an adhesive is applied to the bottom layer and the spine. Themiddle layer 3 is oriented to fit upon the bottom layer and against thespine. Then the middle layer is applied to the adhesive surface of thebottom layer and abuts the spine 12 as shown in FIG. 8. Then furtheradhesive is applied to the middle layer opposite the bottom layer. Asample is then placed within the opening 4 of the middle layer. Thesample is slightly less in thickness than the middle layer 3 and fitswithin the dimensions of the opening 4. Next, the top layer is foldedalong the spine and applied to the middle layer upon the adhesive. Thetop layer is oriented to also match the shape of the bottom layer andthe middle layer. The top layer is also positioned so the tab 7 iscentered upon the opening 4 in the middle layer and above the sample.The three layers are then pressed together to firmly bond them and thesample within a pocket formed in the three layers.

From the aforementioned description, a three dimensional mailer has beendescribed. The three dimensional mailer and its various components maybe manufactured from many materials, including but not limited to singlyor in combination, paper, cardstock, cardboard, open cell foam, closedcell foam, polymers, polyester, polyethylene, polypropylene, polyvinylchloride, nylon, ferrous and non-ferrous metal foils and their alloys,and composites.

Therefore, the foregoing is considered as illustrative only of theprinciples of the invention. Further, since numerous modifications andchanges will readily occur to those skilled in the art, it is notdesired to limit the invention to the exact construction and operationshown and described, and accordingly, all suitable modifications andequivalents may be resorted to, falling within the scope of theinvention.

1. A mailer, for containing a thick sample later opened by a recipient,comprising: a bottom layer, generally thin and planar; a middle layer,generally thick and planar, having an opening therethrough adapted toreceive said sample and joining to said bottom layer; a top layer,generally thin and planar, having at least one lateral edge, areleasable tab, said top layer positioned upon said middle layer, andsaid tab providing access to said opening; and, adhesive applied betweensaid layers thus assembling said mailer.
 2. The mailer of claim 1further comprising: said tab having a fold line located towards saidlateral edge of said top layer, and a scoring line defining theremaining perimeter of said tab.
 3. The mailer of claim 2 wherein saidscoring line forms said tab into a generally rectangular shape and saidmailer is generally rectangular in shape.
 4. The mailer of claim 2further comprising: said tab having a knob extending outward andopposite said fold line and into said top layer for a recipient of saidmailer to grasp and thus to open said mailer.
 5. The mailer of claim 3further comprising: a pocket, forming in said opening and enclosed bysaid tab and said bottom layer, into which said sample is deposited. 6.The mailer of claim 5 wherein said pocket is rectangular.
 7. The mailerof claim 1 further comprising: said top layer having a longitudinal edgeperpendicular to said lateral edge and a flap contiguous with saidlongitudinal edge forming a fold line, said flap folding over said toplayer.
 8. The mailer of claim 7 wherein said flap has the dimensions ofsaid top layer.
 9. A mailer, for containing a thick sample later openedby a recipient upon delivery, comprising: a bottom layer, generally thinand planar having a longitudinal edge, contiguous with a spine upon saidlongitudinal edge and a top layer generally thin and planar having alongitudinal edge contiguous with said spine and opposite said bottomlayer, said spine including two parallel fold lines contiguous with saidbottom layer and said top layer respectively; a middle layer, generallythick and planar, having an opening therethrough adapted to receive saidsample and inserting between said top layer and said bottom layerabutting said spine and joining to said bottom layer; said top layerhaving at least one lateral edge, a releasable tab, said top layerclosing upon said middle layer and said tab providing access to saidopening; and, adhesive applied between said layers thus assembling saidmailer.
 10. The mailer of claim 9 further comprising: said tab having afold line located towards a lateral edge of said top layer andperpendicular to said spine, and a scoring line defining the remainingperimeter of said tab.
 11. The mailer of claim 10 wherein said scoringline forms said tab into a generally rectangular shape and said maileris generally rectangular in shape.
 12. The mailer of claim 10 furthercomprising: said tab having a knob extending outward and opposite saidfold line and into said top layer for a recipient of said mailer tograsp and thus to open said mailer.
 13. The mailer of claim 11 furthercomprising: a pocket, forming in said opening and enclosed by said taband said bottom layer, and into which said sample is deposited.
 14. Themailer of claim 13 wherein said pocket is rectangular.
 15. A mailer, forcontaining a thick sample later opened by a recipient, comprising: atleast two layers, generally thin and planar; a middle layer, generallythick and planar, having an opening therethrough adapted to receive saidsample and joining to said layers; the topmost of said layers, having atleast one lateral edge, a releasable rectangular tab, and said tabproviding access to said opening and having a fold line located towardsa lateral edge of said mailer, and a scoring line defining the remainingperimeter of said tab as generally rectangular; adhesive applied betweensaid layers thus assembling said mailer; and, said tab having a knobextending outward and opposite said fold line and into said top layerfor a recipient of said mailer to grasp and thus to open said mailer.16. The mailer of claim 15 further comprising: the topmost of saidlayers having a longitudinal edge perpendicular to said lateral edge anda flap contiguous with said longitudinal edge forming a fold line, saidflap folding over said top layer.